An inductive device includes an insulating layer, a lower magnetic layer, and an upper magnetic layer that are formed such that the insulating layer does not separate the lower magnetic layer and the upper magnetic layer at the outer edges or wings of the inductive device. The lower magnetic layer and the upper magnetic layer form a continuous magnetic layer around the insulating layer and the conductors of the inductive device. Magnetic leakage paths are provided by forming openings through the upper magnetic layer. The openings may be formed through the upper magnetic layer by semiconductor processes that have relatively higher precision and accuracy compared to semiconductor processes for forming the insulating layer such as spin coating. This reduces magnetic leakage path variation within the inductive device and from inductive device to inductive device.
Legal claims defining the scope of protection, as filed with the USPTO.
1. An inductive device, comprising: one or more insulating layers; one or more conductors; a lower magnetic layer; and an upper magnetic layer, wherein the lower magnetic layer contacts the upper magnetic layer in one or more edges or one or more wings of the inductive device such that a continuous magnetic layer is formed in the one or more edges or the one or more wings, wherein the lower magnetic layer and the upper magnetic layer surround the one or more insulating layers and the one or more conductors, and wherein one or more openings through at least one of the upper magnetic layer or through the lower magnetic layer are to provide one or more magnetic leakage paths for the inductive device.
2. The inductive device of claim 1 , wherein a first opening of the one or more openings is above a first conductor of the one or more conductors; and wherein a second opening of the one or more openings is above a second conductor of the one or more conductors.
3. The inductive device of claim 1 , wherein the one or more openings are formed through the upper magnetic layer at a top of the inductive device.
4. The inductive device of claim 1 , wherein the one or more openings are formed through the lower magnetic layer at a bottom of the inductive device.
5. The inductive device of claim 1 , wherein the one or more openings include one or more holes through at least one of the upper magnetic layer or the lower magnetic layer.
6. The inductive device of claim 1 , wherein the one or more openings include one or more trenches through at least one of the upper magnetic layer or the lower magnetic layer.
7. A method, comprising: removing one or more portions of a first insulating layer of an inductive device from a first magnetic layer of the inductive device; forming a second magnetic layer of the inductive device on one or more portions of the first magnetic layer where the one or more portions of the first insulating layer were removed, wherein the second magnetic layer is formed over the first insulating layer, a second insulating layer of the inductive device, and one or more conductors of the inductive device; and removing one or more portions of the second magnetic layer to form one or more openings in the second magnetic layer, wherein the one or more openings provide one or more magnetic leakage paths for the inductive device.
8. The method of claim 7 , wherein removing the one or more portions of the second magnetic layer comprises: forming a photoresist layer on the second magnetic layer; patterning the photoresist layer; and etching, after patterning the photoresist layer, the one or more portions of the second magnetic layer using the photoresist.
9. The method of claim 7 , further comprising: forming the one or more conductors on the insulating layer, forming the second insulating layer on the first insulating layer and the one or more conductors; and forming the second magnetic layer to cover the second insulating layer and the one or more portions of the first magnetic layer.
10. The method of claim 7 , wherein removing the one or more portions of the second magnetic layer comprises: determining, based on one or more performance parameters for the inductive device, at least one of: a respective shape for each of the one or more openings, a respective size for each of the one or more openings, or a respective location in the second magnetic layer for each of the one or more openings; and removing the one or more portions of the second magnetic layer to form the one or more openings based on the at least one of: the respective shape for each of the one or more openings, the respective size for each of the one or more openings, or the respective location in the second magnetic layer for each of the one or more openings.
11. The method of claim 10 , wherein the one or more performance parameters include a maximum inductance for the inductive device.
12. The method of claim 10 , wherein the one or more performance parameters include a saturation current for the inductive device.
13. The method of claim 10 , wherein a shape for an opening of the one or more openings includes a trench; and wherein a size for the opening includes a length parameter for the trench, a width parameter for the trench, and a depth parameter for the trench.
14. An inductive device, comprising: a lower magnetic layer; a first insulating layer on a portion of the lower magnetic layer; one or more conductors on the first insulating layer; a second insulating layer over the first insulating layer and the one or more conductors; and an upper magnetic layer on the second insulating layer and contacting portions of the lower magnetic layer in one or more edges or one or more wings of the inductive device, wherein one or more openings through the upper magnetic layer and to the second insulating layer are to provide one or more magnetic leakage paths for the inductive device, and wherein the one or more openings are based on one or more performance parameters for the inductive device.
15. The inductive device of claim 14 , wherein the one or more openings comprise: a plurality of holes, wherein a first subset of the plurality of holes have a different size relative to a second subset of the plurality of holes.
16. The inductive device of claim 14 , wherein the one or more openings comprise: a plurality of trenches, wherein a first subset of the plurality of trenches have at least one of: a different length relative to a second subset of the plurality of trenches, or a different width relative to a second subset of the plurality of trenches.
17. The inductive device of claim 14 , wherein the one or more openings comprise: a first array of holes; and a second array of holes, wherein a quantity of holes in the first array of holes is different from a quantity of holes in the second array of holes.
18. The inductive device of claim 14 , wherein the one or more openings comprise: one or more holes, and one or more trenches, wherein a quantity of the one or more holes and a quantity of the one or more trenches are different quantities.
19. The inductive device of claim 14 , wherein the one or more openings comprise: a first array of holes; and a second array of holes, wherein a spacing between holes in the first array of holes is different from a spacing between holes in the second array of holes.
20. The inductive device of claim 14 , wherein a first opening of the one or more openings, and a second opening the one or more openings, have: different shapes, different widths, and different lengths.
Cooperative Patent Classification codes for this invention. Click any code to explore related patents in that topic.
July 29, 2020
May 3, 2022
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